Kits for producing boat hull and other hollow objects



June 21, 1960 w. T. CARLSON ms FOR PRODUCINGBOAT HULL AND OTHER HOLLOWOBJECTS 2 Sheets-Sheet 1 Filed March 2, 1956 w 2 R b 6 C H: WI H .mr H Bl M 2 a w l F 2 Z n u I. h 5 H/ 2 f 4 2 F Y -J 6 v f v 7v n #1 Z June21, 1960 w. T. CARLSON 6 KITS FOR PRODUCING BOAT HULL AND OTHER HOLLOWOBJECTS Filed March 2, 1956 2 Sheets-Skeet 2 INVEN TOR. W/LBEfT 7.' CARLSON United States Patent KITS FOR PRODUCING BOAT HULL AND OTHER HOLLOWOBJECTS Wilbert T. Carlson, 3779 Verleye St., Seaford, N.Y.

Filed Mar. 2, 1956, Ser. No. 569,153

1 Claim. 01. 9--'6.'5)

This invention is an improvement in kits for making boat hulls and otherhollow bodies having a desired configuration, out of suitable plasticmaterial containing fibre glass.

An important object of my invention is to provide a kit for producingthe hull of a boat, and comprising parts that are capable of beingassembled to serve as a form to which fibre glass, which is pliable, canbe added and worked till the materials assume the shape of a hull andthen hardened till it is smooth and finished throughout.

Another object is to provide a kit consisting of ordinary material, easyto obtain, such as cardboard, in pieces of the required outline, adaptedto be bent and set up in juxtaposition, to present continuous areas orsurfaces which conform to the bottom and sides of a boat and over whichthe fibre glass and the plastic substance can readily be coated till theoperation is complete.

A further object is to provide a kit containing members that can easilybe manipulated and combined into a complete structure that has thelikeness of a bull or other hollow object, and is curved wherenecessary; especially along the sides; and retained in curved formationwhen the fibre glass is added and processed till the hull is ready forlaunching. One set of cross members acts as supports or braces for theremaining necessary members, and the kit with all parts in place andconnected imparts to the hull its distinctive lines.

Still another object is to provide a kit for building the hull of a boatand containing members that can quickly be united and given the shape ofa hollow mold form resembling the hull of a boat; and are so preparedthat the fibre glass and other substances which are super added theretowill harden without adhering to said members. Hence when the plasticlayer attains its final stage, all the members or portions of the kitcan easily be removed without distorting the hull or otherwise aifectingit; and discarded or retained for further use.

The foregoing objects and others, and the advantages of my invention aremade clear in the description that follows, and the characteristics ofmy improved boat kit are defined in the appended claims. On the drawingsa preferred embodiment of the invention is illustrated, but I reservethe right to make changes in the shape, size, and arrangement of partsand other details without deviating from the general design in which theinvention resides.

On said drawings:

Figure 1 is a diagram representing in side elevation a boat hull to bebuilt, and disclosing the first step in the practice of my invention,with the positions to be given to the cross supports of the kitindicated.

Figure 2 is a diagram of a vertical cross section of such a hull, as iftaken on line 44 of Figure 1, with the observer looking towards the bow;and likewise showing the positions to be assumed by the cross supportsor bracing members to which the other members are joined to make up abody constituting the entire mold form for the hull.

2,94l,2l3 Patented June 21, 1960 ICC Figure 3 is a similar section onthe line 4-4 as seen when the observer looks toward the stern.

Figure 4 is a top plan of the entire body of the kit showing surfacesthat have the approximate shape of the bottom and sides of a hull.

Figures 5 and 6 are plan views of some of the bracing members of themold form, with the necessary outlines.

Figure 7 depicts in plan how the bracing members are to be set up inplace to be covered by the remaining members.

Figure 8 shows the form and outline of certain members to be coveredwith plastic for the sides of the boat.

Figure 9 shows the outline of sheets of cardboard which are othermembers to receive the plastic for the bottom of the boat.

Figure 10 shows the outline of another member for the sterm of the moldform.

Figure 11 shows one of the cross bracing members in elevation and othermembers in cross section supported thereby.

Figure 12 shows part of several layers of plastic and cloth sheetsbetween them.

Figure 13 is a view similar to Figure 11 indicating plastic containingfibre glass superposed over the outside of the hollow mold form.

Figure 14 presents a detail at the bow of the mold form.

On Figure l, the diagram of a boat hull to be built, is seen from oneside, and the transverse planes marking the positions of the crossmembers for use as parts of the kit, are shown; on Figures 2 and 3, bythe lines 1--1, 2- 2, 3 3, 4- 4, 5-5, 6-6, 7 7, and s s; and the hullwill of course have a stern indicated at 18.

Two of the transverse inside members or braces are illustrated by theoutlines in Figures 5 and 6. Each of said members has a transverse edge9 with a central notch 10, converging edges 11 beginning at the ends ofthe edge 9 and joined to edges 12, that are more convergent andintersecting to form an angle 13 opposite the edge 9. The members 21 and22 occupy the positions in the mold form indicated in Figure l at 11 and22, and in Figures 5 and 6 these members appear in full. The shape ofthe remaining transverse supports or cross bracing members is indicatedon Figures 1 and 2 at the lines 3-3, 4-4, 55, 6--6, '77, and the linesrepresenting the stern 18 between the lines 88. All except the member 18have five sides and the edges 11-11 and 12-12 are respectively equal;and the various members are of diminishing height from bow to stern,with the angles 13 progressively larger.

The full set of brace members to be placed as indicated by the planes ofthe lines 11, 22, 3-3, 4-4, 55, 66, 77 and 8-8, are shown in top edgeview on Figure 9 at 21, 22, 23, 24, 25, 26, 27 and 28 respectively, andall the cross members are inverted and alined on an elongated member orstringer 29 which has the cross sectional shape of the notches 10. Themember 28 having the same shape as the stern of the hull, also has acentral notch, and the stringpiece 29 fits the notches 10, so that allthe brace members are held upright. These members all vary in lengthacross the stringpiece 29, being longest amidships and progressivelyshortertoward the end of the member 29.

When the cross members are thus located and secured in verticalpositions, the other members are laid on, in contact with the edges 11and 12 of the bracing or supporting members. The other members areportrayed on Figures 10, 11 and 12. All cross and other members arepreferably of corrugated cardboard that is stifi. but suflicientlyflexible.

The other members have the outlines shown at 30 in Figure 8 for thesides, and at 31 in Figure 9 for the was inverted. bottom. and at, 28.in Figure for the stern area 18 of the mold form. All the cross membersnow serve as ribs for the other members. The other members-.whieh aresolaid that two members engage: the

edges 11 of the bracing members, one member Stlat each.

The bracing or supporting members may have short projectionsas indicatedat, FiguresS and 6- to engage. small notches; in; the side and bottommembers 30 and 31,. or these: projections and notches may be omitted.

' Atop view of thefinished mold form has the appearance of 'Figure 4.Each side is delineated by the space he.- tweenl anv outer curved line132 and an adjacent inner curved line 33 which represents. the. locationof the chine of the hull, and the area between the lines 33 representsthe hottomrofthe hull. The mold form then resembles an overturned boathull with the lines 32 and 33 curving smoothly-from end to end. i

A cross section of the mold form has. the appearance indicatedjinFigure-1 1, and the pieces 30- present no transverse edges or bends, withangles, along the sides, but have smoothly curved surfaces throughoutand impart to the hullits final shape.

Whena-ll; members of the mold form are assembled, a coating of; wax 32is. put on. the members 30, 31 and 28, and a; layeroi fibre glass 36 islaid on the entire area. of thepieces30, 31 and28, which have theiradjacent. edges in close contact. The fibre glass is given a coating ofpolyester resin which is put on with a roller. The resin fills all theinterstices-and small crevices of the fibre glass andisets and hardens,forming a smooth rigid covering for; the. mold form havingthe curvedformation of a. finished boat. The resin enters into a chemicalcombination with. the glass and. containsa catalyst which hastens. the Pocess.

Several layers. of fibre glass and resin can thusbe put on, andtheresinin each is rolled to render it as smooth as: possible. Thelayers. 36- will be separated by mat 37 of. finer fibre glass; alsopermeated with polyester resin and rolled smooth. The last. or outermostlayer 37 isalso amat of finer fibre glass and is applied inthe samemanner. See Figure 12-. When the hardening is completed, the.wholehullis. strong and rigid and can be put'intothe water; at-once.

Seatscan be built into the hull by using pieces offibre glass laminate,treated with polyester resin in the same way; The. seats will have thenecessary thickness and will. be joined. with polyesterresin at. theends to the. inner facesof the sides of the hull at the selected points.When the. plastic has hardened, the adhesive pieces are cut and: the;inner and outer members are. pulled out. The shell which has taken itsshape from the mold form is hardand smooth and rigid throughout.

If the boat is to have a special gunwale, the upper edgesof the sidemember of the mold form willhave corresponding. lines,- along; the upperedges.

The. entire kit can. be made up with the various-cross and; othermembers in a flat package. The long pieces 30 and 31 can be in severalsmaller pieces or sections, or

in. marine. spore tr n e s y on the inside faces of. the mold form, sothat they can be folded crosswise into shorter lengths. Such division orscore lines if adopted will be so located as to be between the crossmembers. The pieces 30 and 31 can then again be smoothly curved andtheir curved surfaces can be maintained by the pieces ,of adhesive 35 atthe score or; diy-ision lines, and the long member as. before willhavethe desired curved surfaces along the sides. The cross bracingmembers can also be centrally scored and folded, if desired. A moldingstrip can also be affixed to the, gunwale insideon out, and a keelattached to the bottom by putting on fibre glass strips and adding resinas above set forth.

This method of producing the'hull of a boat can be utilized to obtainother hollow bodies by means of inside bracing members and outsidemembers having appropriate shapes.

When the plastic has hardened, the adhesivepieces, 35 arecut and; the.inner and outer members are. pulled out; T e'sh ll i h ha akem s ape mthe d. ions is hard and smooth and rigid throughout.

described; Ir-iy invention, what I believe to be new isz,

A mold term; for a, boat hull. comprising plastic. mate rial, said, formhaving a; string piece extending; irons end to end.- of said form,bracing members, extending crosswise of; the string piece and each-vhaving. a lower-edge engaging the string piece,'the bracing membersalso. having edges at the ends; oi the lower edges converging andintersect.- ing above the string piece, said members decreasingprogressittely in size transversely of. said form from a point in thelength. of said string piece towards the. ends thereof, all said membershaving collectively the. con,- figuration of the hull, withone of saidmembers forming a stern; for said hull; at one, end of the string.piece, the opposite end of the string, piece. extending beyond saidmembers and beingv at" the bow ofi saidhulland projecting past from theadjacent. bracing member, top members laid. side by side afiixedto.said' bracing members, and extending fromone. end. of the hull to theother to. form the. bottom of the hull, side. members afiixed. to saidbracing members adjacent the bottom members, the. top and. side membersengaging the. converging edges ofi said transverse members, the adjacentlongitudinal. edges of said bottom of side members, being connected byadhesive tape extendingover the entire length. oi said. topand sidemembers.

Relierences Cited in the file of this ,patent' UNITED STATES PATENTS833,511 Dean Oct. 16,. 19016 1,361,835 Delagei Dec.. 14, 1920 1,394,726.Gilmore Oct; 25;. 1921 2,348,935 Smith: et: a1 May 1215,1944 2,394,423Bell Feb. 5:, 1946 2,391,049 Sandison Mar. 19,1946 2,409,782 Miller etal Oct; 22, T9416 2,417,586 'Crosely' Mar. 18, 1947 2,425,507 BlakelyAug: 12,. 1947 2,495,640 Muskat Jan. 24*, L950 2662;23:7- Qarey Dec.15,1953

OTHER REFERENCES Low-PressureLarninatesfor Aircraft, BritishBlastics,December 1951, pages415-4-20.

